Journal for food and beverage manufacturers JANUARY 2018 Vol. 45 â€˘ No. 1
Beverage Review & Packaging Review
Smart choice ingredients
A modern spin on cereals and grains
A revolutionary break in gluten enzymes
Raise the bar in metal detection capability
100% Equipment Finance
Food, Beverage & Packaging Equipment
Bridging Finance Growth Finance Asset Finance
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I N D U S T RY U P DAT E
CONTENTS JANUARY 2018 | Vol. 45 • No. 1
Smart ingredients satisfies savvy consumers
06 NEWS Genome fingerprinting boosts food production
29 Beverage Review BeverageREVIE SOUTH AFR ICAN
“Technological advances in steam peeling have created significant advances over lye peeling”
Mpho Makwana to lead Illovo Sugar South Africa
Firmenich acquires Flavourome
The way forward with alternative finance
The first line in combating listeriosis
10 PRODUCT NEWS
What’s new on the shelf?
14 CEREALS, GRAINS & MILLING
Good versus bad carbs
| Volu y 2018
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LED for effective pest control
Compact maize mill for the small entrepreneur Optimise your mill output
The go-to lab for aflatoxin testing
Scan up to five frequencies for added confidence
Tips to reduce false rejects
Consumers prioritise health and sustainability
The latest trends for infant nutrition
How do you get rid of gluten?
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Advanced technologi es in ju processinice g
Kiss sugar goo dbye New markets particles, fibrfor es and
ABB technology modernises oat processing plant
Januar y 2018 | Volume
33 P ackaging
“The role of inks and coatings in packaging can be crucial to the success or failure of printed products”
Ideas powered by chemistry PAGE
40 January 2018 | Food Review
EDITORIAL Editor: Maryke Foulds +27 (0)11 715 8012 firstname.lastname@example.org Assistant Editor: Aarifah Nosarka +27 (0)11 877 6209 email@example.com
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2018 will celebrate
automation and innovation
quick search for food and beverage trends predicted for 2018 reveals a mixed bag of developments. MarketsandMarkets, a revenue impact research and advisory agency, predicts automation and robotics will see mass adoption in many food processing plants. This will assist with operational efficiencies, customer order fulfillment and increased throughput and quality. Food robotics are projected to witness an exceptional growth rate of 12 per cent from 2017 to 2018. Rest assured Food Review will keep you up to date with all the latest developments in this sector throughout the year! In this edition, we glance at how ABB, Roff, Schneider Electric and GEA are assisting companies in meeting industry demands for system integration, compact maize milling equipment and automation technology that will take the sector to the next level. Read more on page 16 now. This year more manufacturers will use terms like natural and functional to launch new products. Research indicates that consumers across EMEA want to focus on developing healthier, nutritious food. Overall 60 per cent of respondents believe this should be industry’s top priority. Harnessing the power of smart ingredients is the way forward; attested to by the swathe of innovation in the category. Find out what is trending in infant nutrition and ways to break down gluten (page 28). Reformulation is also a hot topic this year. The National Council of Provinces has passed the tax on sugary drinks. The tax will levy 2.1 cents per gramme of sugar on all sweetened drinks, with the first four grammes of sugar per 100ml exempt. It is hoped this will act as an incentive to encourage the industry to reformulate its drinks to reduce sugar content (page 30). Consumption of natural beverage products delivering nutritional and functional benefits are projected to grow at a rate of 10 per cent, in volume terms from 2017 to 2018. Demand for exotic fruit purée in particular is growing. See the latest advances in fruit peeling, mixing solutions for carboxymethylcellulose and how to handle delicate processing for particles, fibres and pulp. More on page 31. PACKAGING REVIEW kicks off the year with an in-depth article by Shawn Bezuidenhout from NSI 4 Africa on label production trends for the year. Be sure not to miss it! I hope you enjoy this edition of Food Review! Please let me know of any industry developments, research and news at maryke.foulds@ newmediapub.co.za.
Contributors: Adri Venter, Roné Luttig and Shawn Bezuidenhout ADVERTISING Sales Executive: Anita Raath +27 (0) 82 976 6541 email@example.com Sales Executive: Carla Melless +27 (0) 83 260 6060 firstname.lastname@example.org Sales Executive: Candida Giambo-Kruger +27 (0) 71 438 1918 email@example.com INTERNATIONAL SALES Germany/Austria/Switzerland: Eisenacher Medien Erhardt Eisenacher +49 228 249 9860 firstname.lastname@example.org Italy: Ngcombroker Giacomo Rotunno +39 370 101 4694 email@example.com Taiwan: Ringier Trade Media Sydney Lai +886 4 2329 7318 firstname.lastname@example.org CIRCULATION Circulation Manager: Felicity Garbers +27 (0)21 701 1566 email@example.com PUBLISHING TEAM General Manager: Dev Naidoo Publishing Manager: Natalie Da Silva +27 (0)11 877 6281 firstname.lastname@example.org Production Controller: Rae Morrison Art Director: David Kyslinger JOHANNESBURG OFFICE New Media Publishing, Ground floor, Media Park, 69 Kingsway Avenue, Auckland Park 2092 Tel: +27 (0)11 877 6111 Fax: +27 (0)11 713 9024 POSTAL ADDRESS PO Box 784698, Sandton, Johannesburg 2146 Published on behalf of Media24 by New Media Publishing (PTY) Ltd. MANAGING DIRECTOR Aileen Lamb CHIEF EXECUTIVE OFFICER Bridget McCarney
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EDITORIAL ADVISORY BOARD Two doctorates in chemistry; leader in the field of palm oil; SAAFoST president 1993-2001 and honorary life member; past president, Society of Cosmetic Chemists SA.
Dr Aubrey Parsons With a PhD in biochemistry, an MBA and a Institute of Brewing and Distilling diploma Heidi also serves on the Innovation Hubs BioPark and UNISA’s Life Science advisory board.
HEAD OFFICE Managing director of Symrise South Africa; chairman of SAAFFI.
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Dr Heidi Grimmer Founder, creative director and entrepreneur of Strategic Communications Company (Stratcom).
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Food Review | January 2018
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January 2018 | Food Review
Genome fingerprinting research wins international food security prize in the extreme heat of famine-affected Senegal, Mauritania and Mali could potentially boost the income for one million farming families. The genome fingerprinting research project, led by Dr Filippo Bassi of ICARDA and Professor Rodomiro Ortiz of SLU, was funded by the Swedish Research Council. It uses non-GM molecular breeding techniques to develop a set of durum wheat varieties that can withstand constant 35 to 40˚C heat along the savannah of the Senegal River basin. In this region, farmers grow rice for eight months of the year but the land remains unproductive for the other four months. New durum varieties were developed to grow super-fast so that farmers can grow the wheat between rice seasons. This could produce 600 000 tonnes of new food and generate USD$210 million in additional income for farmers. The wheat features five times more protein than rice, as well as vitamins and minerals – improving diets.
Due to ICARDA’s policy of sharing all germplasm and identity preservation (IP) freely with developing countries, the discovery has wide adaptation potential for other areas hit by increasing temperatures. This ground breaking research was voted, by a panel of expert judges, as the winner of the Olam Prize for Innovation in Food Security – an international prize launched by the global agri-business in partnership with the Agropolis Fondation. Dr Bassi comments, ‘We are thrilled to see our vision of introducing durum wheat into this region recognised by the Olam prize. By working closely with the farmers, we have gained their trust as they can see the benefit of planting this crop which can be easily cultivated with minimum investment. We must create a route to market so we are using the prize fund to foster the establishment of a commercial partnership with the North African pasta and couscous industry.’
New chairman for Illovo Sugar South Africa THE COMPANY ANNOUNCED the appointment of Mpho Makwana as chairman of the board with effect from 1 December 2017. He succeeds Gavin Dalgleish who will focus on his role Mpho Makwana as group managing director. Makwana brings with him almost three decades of diverse experience in executive and C-suite roles in the private and public sectors. He also served as co-chair of the World Economic Forum on Africa (WEF) in 2011. Dalgleish enthuses, ‘Mpho brings with him an in-depth understanding of the potential of South Africa’s economic opportunities, as well as our social realities and the challenges they represent. I look forward to working with him as our business transforms and continues to grow in the country.’
Firmenich acquires Flavourome WITH THIS ACQUISITION, Firmenich will accelerate business growth in this strategic region by gaining direct access to new customers, while operating its own high performing manufacturing facility in South Africa. Flavourome is an established privatelyheld flavours company in South Africa that has been successfully serving the local market since 1998. ‘The Sub-Saharan Africa region, with its population of 800 million, represents a strategic growth market for Firmenich,’ says Patrick
Food Review | January 2018
Firmenich, chairman of the board. ‘As Firmenich has been operating in South Africa for 30 years, this acquisition is a natural extension of our commitment to building longlasting customer partnerships in the region.’ ‘We are proud to have developed strong relationships with leading food companies in South Africa over the years that have supported our commitment to innovation and service. I am also tremendously grateful to all the Flavourome employees who have fueled our success,’ David Wright,
CEO, Flavourome enthuses. ‘Firmenich will be a great partner for our trusted customers and a great longterm home for our employees.’ ‘Building on Flavourome’s established business in South Africa, I am delighted to be expanding Firmenich’s capabilities in this strategic region,’ says Gilbert Ghostine, CEO, Firmenich. ‘This milestone confirms our commitment to shape winning solutions for our customers in South Africa and beyond.’ Building on its longstanding operations in South Africa since 1988, this transaction
accelerates Firmenich’s commitment to developing unique experiences suited to local market needs and preferences. It adds to the group’s strategic commitment to grow in Sub-Saharan Africa, as evidenced by the recent launch of a state-of-the-art flavours facility in Lagos, Nigeria with extensive product development laboratories. The completion of this transaction is subject to clearance by the relevant regulatory authorities (including the Competition Commission) and is expected to close by March 2018.
I N D U S T RY TA L K
Filling the finance gap Alternative finance is also described as finance beyond the traditional. It is defined by the financiers’ area of specialisation – what they specialise in, whom they serve, and how they provide their funding. It does not replace traditional finance but rather functions as a complementary and additional form of funding.
lternative financers are specialists – they focus on a particular need and on a specific audience. Thus, their how is customised to deal with their chosen target market and this in turn targets unique and specific needs. This applies to the funder’s processes and to their level of flexibility around things such as collateral. For example, a SME may have an existing R1 million overdraft (their traditional finance) secured by R 1.5 million collateral. Suddenly they need R5 million for contract, specialised equipment or bridging finance – they need it fast and don’t have that extent of collateral. The traditional funder cannot provide what they need, their process is too long and flexibility is too low. An alternative financier providing specialised equipment finance or bridging finance and focusing on SMEs is ideally positioned to fill this gap. One of the most significant differences between a traditional funder and an alternative financier is in their process. In the case of the alternative financier, they have often chosen to deal exclusively with a customer base, for example SMEs. Thus, this funder has both an affinity and contextually relevant empathy in working with SMEs. Not only do they speak the
same language, but the funder also has an appreciation for the time and material constraints of the SME and has developed processes to cater to this market. This applies most notably to the turnaround time of the funding needed and to the assessment aspect - where flexibility around things such as collateral is vital in making the finance happen for the SME. A traditional funder is unable to meet the deadline of a bridging finance need, submitted on an urgent basis, where the finance is needed as soon as two to three days from time of application. A specialised or alternative funder can do exactly this. A traditional funder is also unable to find creative methods in solving the SMEs lack of high-value collateral in applying for finance. This SME has generally already used their high-value collateral for traditional credit facilities but now needs funding for growth or resolution of a temporary cash flow challenge. An alternative financier can look at such an application in a different way, and has most likely already established alternative ways to make this happen for the SME. •
Spartan – www.spartan.co.za
A BRIGHT AFRICAN FUTURE
THE FRAGRANCE AND flavour industry in South Africa, including suppliers of ingredients, equipment or services will gather for the 16th SAAFFI seminar. The event will be held on 6 March at the Bytes Conference Centre in Midrand, Gauteng. The seminar themed Motion Of No Confidence - promoting a bright African future for the flavour and fragrance industry, will examine the many synergies that make the flavour and fragrance industry in Africa, a particularly exciting one. The speaker line-up includes a world-class researcher who will present the story behind exotic raw materials harvested in the wilds of northern Namibia; a water management expert will give tips on how the industry can help in the alleviation of the local water crisis; an African business expert will present an honest assessment of how to do business in Africa and flavour and fragrance trends will be highlighted. The full-day programme features an impressive line-up of speakers, a hands-on workshop, an inspiring motivational presentation and a networking cocktail event, where the latest tastes and aromas will be showcased. The day offers valuable learning and networking opportunities to people in management, sales, marketing, technical, procurement, R&D, applications, operations and even tertiary level students. Addressing relevant topics of newsworthy interest, and confronting thorny business issues has always been one of the guiding principles of the organising committee. This industry event offers so much for so many. Those who attend are sure to take away added skills, useful information and a solid dose of careeroriented motivation. A day not to be missed by any flavour and fragrance industry professional. Concerns about negotiating peak hour traffic can be happily allayed as the Gautrain transport system serves the venue. For more information, and to book for the event, go to https://saaffi. co.za/ events/.
January 2018 | Food Review
I N D U S T RY TA L K
What is Listeriosis? W ith 61 deaths alone reported to date, this foodborne infection is caused by Listeria monocytogenes. In immuno-compromised people, the elderly, young children, and pregnant women, the disease can develop into sepsis and meningitis. During this stage infection becomes fatal. There are currently seven Listeria species described, with only L.monocytogenes infecting people. In food, it is most commonly associated with processed meat products such as polonies and hams, and certain dairy products i.e. soft cheese. Food products can be contaminated at any stage during processing, putting the entire production line at risk. The pathogen is regarded as a facultative anaerobe, which gives it the ability to grow in modified atmosphere packaged (MAP) food products. It can grow and proliferate at
temperatures as low as 0°C, and can grow in brine and cured products, where it has little competition from other microbes. The pathogen is difficult to eliminate once it establishes itself in a food production facility. The best way to reduce the chances of product contamination is through proper cleaning techniques and use of effective disinfectant products. Ask your chemical supplier for the best possible products to use against this organism. Deltamune offers various options for Listeria testing, including detection and enumeration on environmental swabs and in food products. In addition, MALDI-TOF technology can be applied to find a common link between different isolates; for example, in the final product and the environment or raw materials. Listeria detection is the gold standard and freedom from Listeria can only be determined if 25g of sample is enriched
overnight and then plated & further confirmatory tests performed. The detection tests involve an enrichment step where the sample is placed in a selective growth medium for Listeria. This means that very low levels of contamination can be detected, even as low as one organism in the whole sample. This will however only be an indication of the presence of the organism, and not the level at which it is present. Listeria Enumeration involves only direct plating, and does not include the selective enrichment as it is an indication of the level of contamination on a specific sample. This method is however far less sensitive as it involves a dilution of the sample for plating; which means the minimum amount of contamination that can be detected is 1cfu/ cm2 if a 10cm2 is swabbed. •
Deltamune – www.deltamune.co.za
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Food Review | January 2018
NEW ON THE SHELF Martell VS Single Distillery
launched in SA Martell VS Single Distillery is an innovative blend that reflects the unique distillation style that is the brand’s hallmark, with a richer and more intense expression. It marries eauxde-vie from a single distillery, which results in a supremely smooth blend.
Say hello to
Pesto Princess hummus
The company has announced the launch of its brand new product: hummus. The new addition to its much loved, preservative-free range is free from preservatives and 100 per cent vegan. The iconic pesto jar has found its regular place in most foodie fridges across South Africa. Only top quality, locallysourced ingredients are used.
flour mix range tastes like home
Rise to any cooking or baking occasion with Snowflake’s new flour mix range. Their latest baking innovations feature a truly traditional taste aimed at the South African mass market consumer. Magwenya, Dombolo Flour Mix and Queen Cakes Flour Mix are available nationwide and comes in one kilogramme and 2.5kg packs.
Food Review | January 2018
Kahvé Road's new coffee
The premium coffee and patisserie specialist will now stock its very own premium coffee capsule range. There’s Babylon, a rich dark roast blend or the popular house blend, Petra. Try Machu Pichu, a delicious light blend filled with natural notes of melon and orange amongst others.
Savanna's new rum flavoured cider Savanna has added Blackbeard, to its existing portfolio of premium variants. This delicious premium cider is made with a splash of rum flavour, resulting in a bold new taste for an adventurous drinking experience. It is a special release infused with the sweet flavours of rum but also surprises the palate with hints of raisins, spices and fermented honey.
Bigger is better with the new Score 500ml cans launched by Chill Beverages International. With its double shot of Guarana and a healthy dose of B vitamins, Score has twice the power to release a wave of energy. It is also taurine free. Consumers looking to double their power and ignite their inner drive to reach their goals will want to give Score energy drink a try.
Entries now open for the 2018 New Product Competition
Contact Natalie Da Silva: email@example.com | +27 (0)11 877 6281
C O M PA N Y F O C U S
Smart ingredients satisfy savvy consumers
Innova Market Insights’ top 10 Food Trends for 2018 should inspire marketers and developers to take a fresh look at ingredients smart enough to answer the call for innovation. By Adri Venter and Roné Luttig
onsumers are mindful in their food choices and want to make decisions about health, sustainability and ethical issues. Better-for-you claims continue to be on trend rising from 42 per cent of global launches in 2012 to 49 per cent in 2017 YTD. Environmentally sustainable production methods are top of the list of consumer concerns. Deforestation is a major issue and one of the biggest causes of global warming. Barry Callebaut, a leading manufacturer of high quality chocolate and cocoa ingredients has pledged to be carbon and forest positive by 2025. Its range of products carries the UTZ label – a symbol of sustainable farming. Clean label, natural and organic remain key themes within the ingredients space. This was very evident at the recent FIE show held in Frankfurt, Germany. Clean label (no additives, preservatives and organic) and free from (gluten free and lactose free) claims are seeing strong growth in dairy snack products launched over the last five years. More consumers are reading labels and consider label statements when buying
Food Review | January 2018
packaged food. This has resulted in the removal of unwanted E-numbers. Lallemand Bio-Ingredients offers yeast extracts (a rich mix of protein peptides), which assist in reducing salt while providing a special savoury taste and improved organoleptic qualities in a multitude of food products. The amino acid profile and taste of yeast extract are similar to a meat bouillon. The product portfolio includes: •P rime-Lyfe 175A displays a unique concentrated combination of peptides and amino acids, including glutamic acid for a clean flavour and a more powerful taste enhancement. It is suitable for a variety of savoury applications. •H igh-Lyfe 605A is a yeast extract rich in glutathione the main active ingredient in increasing continuity, mouthfeel and
thickness in umami solutions. Intensified taste perception allows salt reduction, enjoying a healthier, rich and balanced taste. Products containing fats, oils or flavours are prone to oxidation resulting in unpleasant odours and the possible formation of carcinogenic compounds. Vitiva has done extensive studies on rosemary extracts and their efficacy in shelf life extension and other health benefits. Rosemary extract is a natural anti-oxidant containing carnosic and rosmarinic acid as active ingredients used in food and non-food products to extend shelf life. It works by scavenging free radicals formed when products are exposed to heat, light or foreign substances. They are odourless, heat stable up to 240⁰C, water and oil soluble. This renders it the antioxidant of choice in clean label application.
“Better-for-you claims continue to be on trend rising from 42 per cent of global launches in 2012 to 49 per cent in 2017 YTD”
C O M PA N Y F O C U S
IN SEARCH OF LESS On trend is low alcohol content beverages, less sweet i.e. slightly sweet; hints of flavour; lighter and thinner textures and even portion sizes. This all ties in with consumers continuing to look for ways to eat and drink more healthily. Palatinose™ developed and supplied by Beneo is a slowly, yet fully digestible carbohydrate, which supplies the body with energy in a slower, balanced way over a longer period of time than conventional carbohydrates. This unique carbohydrate is the perfect fit for low- and zero alcohol beers, which often lack body and mouthfeel. Palatinose optimises the sensorial profile and taste by increasing body and mouthfeel. It also has a positive impact on blood sugar levels. The story of stevia is constantly changing. Not long ago, it was a little known, plantbased zero-calorie sweetener that worked well in some food and beverage applications. Due to PureCircle’s research, development and innovation, a range of stevia-based sweeteners with sugar-like taste and zero calories is now available. These new, from-nature sweeteners are often used in combinations with each other and work well in many formulations to reduce sugar and adjust sweetness. PureCircle recently announced StarLeaf stevia, a variety that contains a >20 times increase in the most sugar-like glycosides, making it a favourable choice for sugar reduction and lighter enjoyment. Beneo specialty rice ingredients enhance the texture of baked goods enabling manufacturers to offer thinner, crispier biscuits and crackers to satisfy consumer preference. In wheat-based recipes, pregelatinised waxy rice starch can be used to achieve the required texture and improves final product characteristics, such as increased crunchiness in crackers. At the same time it reduces breakage in these products.
their extremely long shelf life and high solubility in hot and cold liquids, these granules are suited to flavoured teas and tea blends, coffee capsules and instant beverages. Granules are distinguished by high mechanical stability and excellent flowing properties. Frey+ Lau maintains an extensive assortment of granules in all conceivable flavour varieties, from bergamot to spearmint; natural pear to wild berry and in many sizes, shapes and colours.
“Consumer desire for healthier lifestyles results in purchasing decisions being driven by heightened holistic wellness benefits” SAY IT WITH COLOUR Consumers connect bright colours with better health. Vibrant Harvest’s whole food and vegetable powders are sustainably produced from fresh, high quality fruits and vegetables. It is a sure way to fill products with equivalent servings and nutrients of conventional fruits and vegetables. The patented radiant zone drying method assures excellent retention of nutrients and antioxidants. Today’s consumers want their nutrition from whole foods. Claims for natural, minimally-processed and understandable sourcing are easily achieved with this range of products.
SNACKS TO MINI-MEALS Sustained energy and controlled blood sugar levels are two important considerations for smart snacking. In this sense, Palatinose is the perfect energy fuel choice. It is a natural constituent of honey and the only carbohydrate, which is fully digestible yet slowly released in the blood stream. The glycaemic index of this carbohydrate is only 32 and ideally suited for diabetics, sports enthusiasts and on-the-go consumers. Dairy- and plant based proteins are an important consideration in snacking applications to achieve cost optimisation and digestibility ratios over a wider range. ADM offers cost-effective solutions with the Arcon range of soy concentrates enabling developers to achieve economical protein content claims. The ADM range of bean powders (Navy Bean, Red Bean etc.) is gaining traction as a cost- effective wholefood ingredient in snacking applications. The quest to meet consumer demand is becoming more challenging, considering environmental sustainability, clean label development, public health policies and technical attributes. Consumer desire for healthier lifestyles results in purchasing decisions being driven by heightened holistic wellness benefits. These shoppers will certainly continue to demand expanded choice, and food and beverage companies that successfully address this demand will be rewarded. Savannah is proudly affiliated with all mentioned manufacturers. •
Savannah – firstname.lastname@example.org
BEYOND THE COFFEE HOUSE Coffee and tea keep gaining traction with endless innovation opportunities across categories. With the taste and experiential associations of coffee and the healthy image of tea, the industry is using these ingredients and flavours outside the hot drinks, iced tea and coffee sub-categories. Interest in tea is spiking due to its health benefits and exotic taste profiles. Capso technology from German company Frey+Lau encompasses a highly innovative process for encapsulating flavours distinguished by authentic flavour profiles and retention of high-end notes. These flavour granules are produced in the form of high-quality pearls, activated when they are in contact with water. As a result of
January 2018 | Food Review
CEREAL S, GR AINS & MILLING
for harnessing good versus bad carbs Consumers’ quest for better carbohydrates and fewer carbohydrates is creating a wealth of large and growing opportunities, even in the mass market. This is according to 10 Key Trends in Food, Nutrition and Health 2018, the annual trends report from New Nutrition Business.
“...the idea that each of us has unique nutritional and metabolic needs is becoming an accepted fact”
he trend is fuelled by emerging science that’s associating carbs with health issues such as weight gain and blood sugar response. ‘Consumers are experimenting with lowering their carb intake, or improving the carbs they eat, in the hopes of benefiting their health and/or their waistlines,’ says Julian Mellentin, author of the report. ‘Companies are responding to these opportunities by adopting one or more of five strategies,’ Mellentin explains. ‘The biggest of these strategies is reformulation – not only substituting whole grains for refined wheat, but offering gluten-free variants to take away a big digestive health issue that many consumers have with carbohydrates.’ One area that is moving quickly is the re-formulation of pasta. Several companies are now offering pastas and noodles, made not from wheat but from dried peas, beans, lentils and chickpeas. Another powerful strategy many companies are following is that of greener carbs. Convenient vegetables, and vegetables in forms that can be substituted for traditional
Food Review | January 2018
carbohydrates, are the fruit of creative NPD and skilful food technology. The good carbs/bad carbs debate shows that key trends often overlap with, and fuel, one another. Digestive health, plant-based and snackification are all connected to this trend. Another powerful driver of good carbs is personalisation. People are going online, doing their own research and crafting their own eating style that they believe matches their needs as individuals. The belief that diet cannot be one size fits all is gaining ground. For about 50 per cent of the population, the idea that each of us has unique nutritional and metabolic needs is becoming an accepted fact. These people, no matter what official dietary guidelines say, look upon carbs as a menu from which they feel free to select some as good, and reject others as bad. This creates opportunities for companies willing to respond creatively to this much greater variety of needs and beliefs. •
10 KEY TRENDS FOR 2018 ARE:
•D igestive wellness – a long-term driver of growth •G ood carbs/bad carbs – five strategies for growth • Plant-based – NPD and convenience transforms plants • Protein – a growing market for plant, dairy and meat sources • Personalisation and fragmentation – where’s the opportunity? • Beverages redefined – sugar concerns drive opportunity • Sugar – strategies for this new dietary demon • Fat – consumers’ embrace of fat gives the green light to taste • Snackification – a route to success that’s central to strategy • Inflammation – an outlier trend that’s rapidly gaining ground.
An extensive range of
Seed, Grain, Flours, Pulses and Proteins to support your business. Improve your product offering with local and imported quality products
Linseed seed Pumpkin seed Poppy seed Chia seed Caraway seed Aniseed Mushroom popcorn Wholewheat couscous Couscous Dehulled Oats Rolled oats Crushed Wheat Crushed rye Dehulled millet Quinoa Red quinoa Bulgur wheat
Pearled barley Dehulled buckwheat Black buckwheat kernel Amaranth Polenta Chickpeas Sugar beans White kidney beans Black eyed beans Mung beans Black beans Red kidney beans Whole yellow peas Whole green peas Green split peas Yellow split peas Red split lentils Brown lentils Pea protein
Johannesburg: 8 Jacobs Street, Chamdor, Krugersdorp, South Africa, 1740 Tel: +27 11 762 5261 • Fax: +27 11 762 4111 Cape Town: Tel: +27 21 552 0456 • Kwa-Zulu Natal: Tel: +27 33 346 0639 email@example.com
CEREAL S, GR AINS & MILLING
A modern spin on ancient oats
The ABB system runs continually to ensure maximum output
Global ingredients and solutions supplier Tate & Lyle, has modernised its Swedish oat processing plant with ABB technology. The modern and expanded factory features variable speed drives, motors, motor control cabinets and valve positioners.
he global market for speciality food ingredients, including health and wellness products, is high and growing, with annual sales of US$51 billion and annual growth of four to five per cent. Oat ingredients are actively involved in this trend as they offer some key nutritional and functional benefits. Oats contain beta glucan, a soluble fibre, proven to lower cholesterol and reduce post-prandial glycaemic response. ‘We’ve seen a more than tenfold increase in capacity with the same number of shift operators compared to four years ago,’ says Annika Werneman, Tate & Lyle plant manager. ‘It’s a huge change in such a short time. It means that we’ve gone from a low-level facility to one that can deliver high quality product to our customers globally.’ Automation technologies run critical food processing equipment including pumps and decanters, while material handling machinery are used to transport dry food products. ABB delivered automation equipment including
Food Review | January 2018
85 variable speed drives (VSDs) with different power ratings, ranging from 0.37 kW to 55 kW, as well as its range of MNS 3.0 motor control cabinets and low voltage motors to the facility. 44 Digital Electro pneumatic positioners TZID-C with Hart protocol for the control valves were also installed. ‘We needed a process that was highly automated and could run 24 hours, seven days a week, all year long,’ Werneman continues. This meant building a system that enabled Tate & Lyle’s engineers to digitally interact with the system, commission devices, and diagnose performance deviations or failures from anywhere in the world. This would not only help ensure operational consistency, but also reduce the total cost of ownership by enabling staff to manage processes without being physically present at each site. Such interactivity was enabled by ABB’s inclusion of remote monitoring and fieldbus flexibility in the drives. ‘I like that ABB designed the equipment so the fieldbus responsible for device control
is split from the fieldbus used for asset management,’ explains Leo Dijkstra, power and controls team leader Europe at Tate & Lyle. ‘This ensures that I can make any changes to the configuration of the devices without the risk of the whole network going down.’ At Tate & Lyle, management places great importance not just on what they do, but on how they do it. ‘We are working continuously wherever we can to reduce the environmental footprint of our operations,’ says Dijkstra. ABB was well placed to help as it has developed a portfolio of products and solutions that improve industrial energy efficiency. In our pump applications alone, we are using up to 50 per cent less energy thanks to the variable speed drives, and have been running non-stop for the last two years without a single failure,’ Dijkstra concludes. •
ABB – www.abb.com
CEREAL S, GR AINS & MILLING
Flies be gone
entokil is constantly thinking of innovative ways to save you money and deliver a quality, innovative pest control service. ‘We understand the challenges that fly control can bring to businesses. 45 per cent of businesses that have suffered fly infestations in the past five years report a high or moderate concern about loss of income,’ explains Nathalie Leblond of Rentokil.
INTRODUCING LUMNIA, RENTOKIL’S NEW LED RANGE OF FLY KILLERS For three years, Rentokil has been analysing LED technology and testing its new units against the market. Rentokil believes the technology is now at a point that its benefits can be leveraged for customers due to lower cost LEDs and enhanced performance. Months were spent testing at the Rentokil Global Science Center - working with the key players in developing this technology. Prototypes were trialed across the world, while feedback was gathered from customers. Its efficacy was then tested against Rentokil’s efficacy measure, Half Life. Finally, the
company could announce the launch of its new fly killer range, Lumnia. ‘In a world that said LED didn’t work for electronic fly killers, Rentokil has made LED work. We have 12 patents across the unit and LED strips to prove it. Lumnia is the first electric fly killer range in the world to use LED lighting rather than traditional blue-light fluorescent tubes. The range comes on the heels of a partnership with a leading manufacturer of LED. The switch from traditional fluorescent tubes allows for an estimated energy consumption reduction of 60 per cent versus comparable units’ Leblond explains. In addition to energy saving benefits of LEDs, the unit has different lighting settings to suit the specific requirements of a specific location. An active lighting mode that adapts output according to the ambient lighting levels on premises further reduces energy costs. ‘The unit has improved it serviceability, reducing the number of times that our fly killers need to be serviced at heights, and offers several energy modes: high, medium
Rentokil’s new Lumia range of LED fly killers
and low. It also offers an active mode, which adapts to UV levels, adapting continuously to the conditions of the customers’ premises. This unit has a modular design which can be used as a glue board or encapsulation unit, and offers a control or monitor option depending on infestation levels,’ Leblond concludes. • *Opinion Matters Research 2015 commissioned by the Centre for Economics and Business Research for Rentokil.
Rentokil Initial – www.rentokil.co.za
Lumnia . The first and only electronic fly killer to use LED technology.
Low energy LED lamps: 3 year life span consuming less energy Get in touch with us! 0800 736 86545 or www.rentokil.co.za
January 2018 | Food Review
CEREAL S, GR AINS & MILLING
Super maize meal is here Roff Industries has introduced the Roff R-10, a compact maize mill that can produce super maize meal at 24 tonnes per day and 540 tonnes per month.
he R-10 is ideal for entrepreneurs who would like to enter the maize meal market on a small scale. Roff Industries’ director, Isak de Necker explains, ‘The R-10 offers entrepreneurs the opportunity to enter the retail market with a maize mill that delivers a competitive advantage with top quality maize meal and excellent extraction rates.’ This new design is smaller, but still a box contains everything you need to process complete mill packaged in the R10 box. maize into quality maize meal. Like all Roff ‘It’s challenging to design a cost-effective mills, the R-10 is reliable and the operation is small mill since you still need all the milling low maintenance and efficient. processes of a large mill to ensure the same top-quality maize meal. Our design CLEAN LABEL AND team rose to the occasion. Their dedication NATURAL INNOVATION to innovation is embodied in the R-10,’ Ingredion, took home the top prize in the elaborates Charl Marais, managing director of Clean Label and Natural innovation Fi Roff Industries. Europe Innovation Awards, held in Frankfurt, The R-10 is almost half the size of the Germany in November. The company received flagship R-70 and occupies only 80m2 – ideal special recognition for its Homecraft Create for smaller operations. If applied in smaller 835 and 865 multi-functional communities through rice flours. community-based Suitable for highly mills the R-10 can be demanding, clean label instrumental in serving applications including consumers by giving soups, sauces and ready them access to the meals, the rice flours top-quality maize meal deliver the same level of they deserve. performance as functional An additional native rice starches, while advantage of the enabling a consumerR-10 is that it’s based Ruediger Schock preferred rice flour label. on a containerised , Charlot te Commarmond an d Pierre Pere z With moderate-to-high mill. This means the of Ingredion process tolerance, they also equipment can be deliver superior texture easily traded in when stability over shelf-life, the entrepreneur is ready improved opacity and gluten-free appeal. to upgrade the R-10 to a R-70. Homecraft Create 835 and 865 multiAs with the R-70, ROFF Industries offers functional rice flours enable food producers complete assistance, from supplying to to substitute ingredients such as modified project management and full turnkey starch, in favour of consumer-friendly flour services. The installation of the R-10 can be labels, without compromising product quality. completed within 10 days and pre-assembly Charlotte Commarmond, senior director, takes place in the factory to ensure quality. marketing and innovation at Ingredion The R-10 is simple yet functional and comes EMEA, says, ‘During a time when clean and standard with all the necessary equipment natural foods have never been in greater and parts. The only components the client demand, we are delighted to produce an should provide are the building, a water point ingredient that supports the ultimate clean and electrical supply to the panel. The R-10
Food Review | January 2018
The Roff R-10 compact maize mill
label claim. Our Homecraft Create 835 and 865 multi-functional rice flours meet consumer demand for healthier products and satisfy the preference for flours and ricebased ingredients. ‘Our research shows that rice is not only well-recognised by consumers as a widelyused ingredient, but it also has positive associations with being natural (55 per cent), healthy (51 per cent), real food (39 per cent) and easy to digest (36 per cent). 78 per cent of consumers accept rice flour in soups, sauces and ready meals. No other tested texturiser ranked higher. ‘As pioneers of clean label ingredient solutions, we are thrilled to have been recognised by the industry for our innovations.’ There are four fundamental areas in which Homecraft Create 865 and Homecraft Create 835 multi-functional rice flours demonstrate innovation. Firstly, they enable manufacturers to replace fat or protein while sustaining creaminess and mouthfeel. Secondly, they can deliver improved product quality due to their high texture stability over shelf-life and ability to prevent syneresis. Thirdly, they enable the development of gluten-free sauces with an authentic flour label and a texture and opacity like wheat flour. Lastly, they can offer increased consumer appeal through the ultimate clean label ingredient, which supports a natural and premium positioning in highly demanding applications, such as soups, sauces and ready meals. •
Roff Industries – www.roff.co.za Ingredion – www.ingredion.com
The new, compact R-10 maize mill Available Now!
Compact maize mill that can produce super maize meal at 24 ton per day and 540 ton per month. Occupies only 80m2 Contact us today. Tel: +27(0)56 212 2697 firstname.lastname@example.org www.roff.co.za
CEREAL S, GR AINS & MILLING
Systems upgrade for an ageing mill
Premier FMCG currently operates 16 bakeries, five wheat and two maize mills, a sugar confectionery plant and 24 distribution plants across South Africa, Swaziland and Lesotho. Its wheat mills have a total capacity of processing 800 000 tonnes of wheat per annum. Two are designed specifically to mill flour for specialist industrial customers.
xisting control systems in Premier’s wheat mills were ageing and a lack of support and spare parts presented an operational risk. The plant expanded with a new wheat mill to increase production capacity. As part of this expansion, Premier decided to replace and modernise the control, automation and electrical systems. The aim of the upgrade was to: •M odernise control systems •S tandardise control software •A pply power metering and variable speed drives to monitor, control and optimise energy usage.
INNOVATIVE SYSTEMS PlantStruxure PES, Schneider Electric’s innovative process automation system, is designed to meet the demand of production facilities with hybrid control applications. Premier was impressed by all functionalities provided by PES to efficiently manage their process and energy use, starting with its single environment for engineering, operation and maintenance. They also liked the fact that PES is built on Ethernet, an open industry standard, which allows the seamless integration of system components like smart devices. It provides connectivity
to business systems for fast and easy information exchange. Long-term backup and support are important considerations for Premier and the reason they prefer to partner with large companies. Schneider Electric offers a large pool of engineering resources and support services.
FULLY CONNECTED ARCHITECTURE Built on a single PlantStruxure PES platform, the system consists of redundant supervision servers and clients, connected to multiple controllers, remote I/O stations and 500 plus variable speed drives on an industrial ethernet network. Architecture implemented by Schneider is mature, has a proven track record, and is based on a wide range of its ethernet devices. It is robust, using redundant Ethernet ring networks, as well as flexible and scalable for easy expansion in the future. PlantStruxure PES offers a single, object-oriented database that allows it to maintain consistency – during engineering and throughout the system’s life cycle for complete traceability and easy modification or extension during operation and maintenance.
PES’ all-in-one configuration functionality means faster system design from a single data entry point. Through the application manager, the application is easily replicated, using most models. The design can be based on a hierarchical organisation for easier evolution of the installation. The system was engineered from scratch, without reusing existing code, to leverage the benefits of an object-oriented platform. A multi-phased approach was used to switch over the existing system to the new system during plant shutdown/maintenance period so that only small portions of the plant were impacted at any given time. The flow of water and wheat though each of the plant’s processes (in tonnes per hour) is continuously monitored and displayed on the supervision system. This is integrated into Premier’s intranet, but not directly to the internet. Remote access and control is available to limited users on the internet, from any of the sites around the country.
“PlantStruxure PES, Schneider Electric’s innovative process automation system, is designed to meet the demand of production facilities with hybrid control applications” PlantStruxure PES collects process, quality and energy data from the plant and generates detailed reports to support effective decision making. It seamlessly connects to the production and business system to ensure that the right people have access to the information they need. Reports have been configured to present plant management and accounting staff with the operations and production data from the plant. They can generate production and mass balance reports to determine the amount of wheat and flour processed by each section of the plant. Flexible reports allow analysis over any desired time frame. The technology also provides Premier with a mechanism to back up its system configuration as well as process data like setpoints, tuning parameters etc. Engineering licenses are tailored to the size of the application. Runtime licenses are tailored to the object counts and architecture of the application i.e. separate floating licenses for servers, clients and web clients. •
Schneider Electric – www.schneider.electric.com
Food Review | January 2018
CEREAL S, GR AINS & MILLING
GIANT TARGETS local market
Bureau Veritas, the renowned international accreditation, testing and analyses global giant, has unveiled its technologically savvy, state-of-the-art microbiological laboratory in Brackenfell, Cape Town. The launch reinforces the company’s investment and commitment to growth and development in Africa.
he facility is designed and engineered to focus on the food and agricultural sectors in the Western Cape. M&L’s Laboratory forms an extension of the Bureau Veritas Johannesburg branch - extending the company’s national footprint. Automated equipment will improve testing lead times and efficiencies of delivery. This will benefit customers by saving time during the manufacturing process and ensuring
product safety and quality. Testing results are traceable and reported automatically with the refined Laboratory Information Management Software systems. The facility is a proudly environmentally friendly green facility with waste being reduced by more than 50 per cent thereby contributing towards sustainable and socially eco-friendly operating practices. Commenting at the launch, director of M&L
Laboratories, Joanne Barton enthuses, ‘We are proud of our unique, state-of-the-art facility which houses new age equipment to enhance our technical offering. In our drive to get closer to our customers and provide a service that includes faster analysis time and traceable results which reduce human error; we see ourselves offering a unique solution in the marketplace – all under one roof. ‘Our accessible facility means we are in the hub of the food and agri centre in the country, eliminating the need to transport samples. Sophisticated and highly accurate technology means our clients will receive technically competent analyses from our highly skilled professional team in a shorter timeframe. In this way, we add value to their supply chain process.’ Innovative technology replaces conventional testing methods. Benefits of shorter timeframes are particularly useful when dealing with high risk food products. This in turn enhances food safety. In the agricultural sector, reduced lead times on testing for pesticides, aflatoxins, heavy metals and the like enhance product safety. This ensures that the customer ultimately enjoys a safe and healthy experience. Water testing will also be conducted in the new facilities to ensure product safety and a longer shelf life. The investment in the South African market marks the creation of jobs for technically skilled workers, microbiologists and technical sales specialists. BV is poised to deliver the highest levels of service to its customers backed by Barton’s proven track record of technical competence and leadership skills. Under her guidance the laboratory is well set to achieve its targets. The headquarters for Bureau Veritas’ South African operations are in Johannesburg, South Africa with branches in Bronkhorstspruit, Rustenburg, Richards Bay, Durban, East London and Port Elizabeth. •
M&L Laboratory – www.bureauveritas.co.za Cutting edge extrusion technology
GEA EXTENDS PORTFOLIO WITH EXTRUSION AND MILLING TECHNOLOGY WITH THE CONCLUDED acquisition of the Italian Pavan Group in November 2017 the Düsseldorf engineering group GEA purchased a leading supplier of extrusion and milling technology for processing all kinds of fresh and dried pasta, pelleted snack products and breakfast cereals. The acquisition is an important milestone in the declared growth strategy for further expanding food processing activities for the group. The Pavan Group is a strong and solid organisation, operating in the food industry as global supplier of industrial solutions, from the handling of raw
materials to the final packaging. The Italian specialist offers a wide range of solutions pasta production: long and short-cut dry, nest shaped, pre-cooked, couscous and technology for filled, flat, and extruded fresh pasta, convenience food and gnocchi. The company provides dies, cutting systems, die washing equipment and packaging lines in this segment. The secret is the selection of the appropriate temperature and the speed at which the raw material is pressed through a nozzle. The nozzle design is crucial. Extensive application and
equipment know-how is required to know how to combine the various machines around the extruder. The GEA plans to build up on the 70-year expertise, its broad product range and sustained investment in research and development of Pavan Group and to grow business continuously, for example in geographical terms too. In the future, GEA will be able to offer customers new high-quality and innovative process and automation solutions for deployment in standalone installations, but also complete turnkey systems.
January 2018 | Food Review
M E TA L D E T E C T I O N
Detect the undetectable Thermo Scientific Sentinel has introduced its Multiscan metal detector to market. The company claims the unit can locate previously undetectable metal contaminants. Lauded as a first-of-its-kind metal detection platform, the units rapidly scan up to five frequencies to help food and consumer goods manufacturers to confidently find ferrous, non-ferrous and stainless steel metal contaminants in products.
he Multiscan metal detector enables users to identify contaminants up to 70 per cent smaller in volume than previous technologies, including the Thermo Scientific APEX 500 metal detector. ‘The unit’s functionality raises the bar for detection capability, flexibility and performance,’ notes Bob Ries, lead product manager, product inspection for Thermo Fisher Scientific. ‘Scanning many frequencies with one detector means the probability of detection exponentially increases. This reduces the risk of costly contamination events that require rework, scrap and recalls. With the Sentinel, it’s Don’t get caught by contaminated ready meals
like having five separate metal detectors combined, each looking for contaminants at a different frequency.’ The Sentinel metal detector is designed for a wide range of applications, offering improved performance for products such as dairy, meat, poultry, fruit, vegetables and bread amongst others. Inspecting these products for foreign objects is especially challenging. This is partly due to the phenomenon of product effect. This is where the signal from a type of metal can be hidden inside the electromagnetic response of the product. With prior technology, switching the operating frequency could make the hidden metal detectable, but in turn render other types of metal undetectable. Thermo Fisher designed the Sentinel to alleviate this problem by scanning multiple frequencies. This increases the probability of finding random sizes, shapes and types of embedded metal foreign objects. The Sentinel metal detector has the same footprint and aperture location as the APEX 500 metal detector. Users seeking to upgrade to the new platform can do so easily.
ELIMINATE RISK IN READY MEALS Ready meals are a growing, multi-billion Rand market globally. The need for contamination-free products is critical and failure to detect foreign objects in food can lead to costly recalls and even destroy a brand. Anritsu Infivis is a leading supplier of the preventative measures food manufacturers must take to ensure consumers don’t end up with a mouthful of metal, bone or glass fragments. The technology is
Food Review | January 2018
The unit can scan up to five frequencies
suitable for all types of convenience food. The company’s range of X-ray and metal detection systems can identify contaminants – whatever their size, shape and location in fresh, frozen and ambient products. This ensures ready meals are safe for consumers, offering manufacturers peace of mind. In addition to accurately detecting the smallest fragment of a contaminant in food products, the range of equipment features advanced signal processing technology and high-precision machine control systems. This impacts on false rejection rates. The XR-75 Series of X-ray Inspection Systems are designed to help safeguard the integrity of food from contaminants. The SSV Checkweighers are versatile and robust, food safety technology that offers high quality and performance. The ultra-sensitive XR75 can also identify product shape defects and packaging integrity, while reducing the lifetime cost of ownership by over 20 per cent compared to other systems. This is thanks to the company’s Advanced Long Life Technology, which incorporates low power design and longer equipment life. Protecting consumers from contaminants in the food chain is paramount for both the retailer and supplier. Finding the smallest foreign body in food can be seriously damaging financially and to a company’s reputation. Anritsu X-ray inspection systems are renowned for satisfying every regulatory safety standard around the world. Ultra-HD technology can detect ferrous, non-ferrous and stainless steel sphere at production line speeds down to 0.2mm.
M E TA L D E T E C T I O N
The company designs and develops all its products in-house to support every solution with 100 per cent confidence. Its safety solutions for ready meals have earned global recognition for their outstanding performance, capability and credibility. Recent investment in new infrastructure and staff in its UK operation to meet the growing demand for food safety equipment is a statement of intent by Anritsu, to provide the highest quality detection systems and after-sales service on the market.
ENHANCED CHEESE QUALITY
“Scanning many frequencies with one detector means the probability of detection exponentially increases. This reduces the risk of costly contamination events that require rework, scrap and recalls”
Specialist South African cheese supplier, the Famous Brands Cheese Company has enhanced its stringent quality control standards with the adoption of Ishida X-ray inspection technology. The company has installed an Ishida IXGN-4044 X-ray inspection system to identify potential foreign bodies in three kilogramme packs of diced mozzarella cheese supplied for pizza toppings. The flexibility of the system enables the machine for weight estimation. Prior to the installation of the IX-GN, the Famous Brands Cheese Company used metal detection for its quality inspection process but was attracted by the much wider capabilities of X-ray technology. ‘With the IX-GN-4044 we can search for glass and different metals. This means we can make our products even safer for our State-of-the-art x-ray technology
customers,’ explains Richard Rudman, operations manager. The Ishida IX-GN-4044 is in continual operation 24 hours a day, seven days a week, handling 20 tonnes of diced cheese every day at around 18 bags per minute. The speed of the line is currently governed by the capabilities of the bagmaker. The X-ray system has the capacity to operate at much higher speeds, providing a valuable element of future-proofing for the cheese company’s continued growth. ‘The machine is userfriendly, easy to operate and quick and easy to clean. Installation and training took only three days. The machine then went into production straightaway and has been operating reliably ever since,’ Rudman notes. The Famous Brand Cheese Company approached Ishida for an X-ray solution as an existing user of the company’s multihead weighers. ‘We were already familiar with the technical sophistication and reliability of Ishida equipment,’ he concludes. ‘The production detection levels and consistency of the IX-GN-4044 are much higher than X-ray solutions offered by other suppliers. The weight estimation feature was an additional very interesting feature for us. We are delighted with the enhancements the Ishida X-ray inspection system has made to our quality control.’ •
Anritsu – www.anritsu.com Ishida – www.ishida.com Thermo Fisher – www.thermofisher.com
TIPS TO REDUCE FALSE REJECTS AS TECHNOLOGY BECOMES more advanced, food manufacturers and processors must pay careful attention to the capabilities and specifications of these systems. A high number of false rejects slows the food line, wastes product, and ultimately cuts down on profit through productivity losses and product re-runs. •C onveyor system issues False rejects are often caused by problems with the conveyor system. Loose fittings, worn bearings, or improperly set metal-detector heads may result in a high number of false rejects. Ensure all mechanical parts of the line are in good, working order and that new components are per manufacturer specifications. •R adio frequency interference Most metal-detection units operate through a radio frequency system. Other equipment using similar technology in a small space may cause interference and other types of equipment may also cause improper reception of appropriate radio waves. If the wave doesn’t go through as it should, product pass through will be identified as a reject. •P roduct uniformity Some food products, meats, cheeses, and some liquids, change consistency. As the temperature and humidity may change throughout the day, products that have a high salt or water content may change in conductivity or solidity. This may lead to inconsistency in terms of how radio frequencies pass through food. Changes in the rate at which radio waves penetrate the food product may result in false rejects. Utilising automatic detection technology can reduce false rejects, but regulating environmental conditions, such as heat and humidity is essential. •A utomatic adjustments Most new machinery allows for automatic adjustments, but it must be appropriately calibrated to work. Manufacturers should take advantage of higher-tech settings, reducing the chance that changes in material will cause false rejects due to human failure to recalibrate or adjust.
January 2018 | Food Review
BREAKTHROUGH in lowering cholesterol Wacker has released the latest results on the effect of its nature-identical hydroxytyrosol HTEssence on heart health. A recent human clinical study demonstrates that HTEssence can significantly reduce low density lipoprotein (LDL) cholesterol.
educing LDL has been found to support heart health. Hydroxytyrosol is a highly effective antioxidant found in olives with positive effects on blood pressure, joints and the immune and cardiovascular systems. Wacker is producing the first nature-identical hydroxytyrosol free of unwanted byproducts and with a defined amount of active ingredient. HTEssence offers an excellent price/performance ratio and is easy to process in dietary supplements and functional beverages. Hydroxytyrosol, a secondary plant metabolite, is considered a highly effective antioxidant. It reportedly strengthens the immune system, lowers blood pressure, reduces inflammation and improves bone and joint health. It is said to have a positive effect on blood lipid management, an effect that – according to the US National Cholesterol Education Program (NCEP) – can support heart health. A recent clinical study has now shown that Wacker’s nature-identical hydroxytyrosol HTEssence has a positive effect on blood cholesterol. In a randomised, double-blind, placebo-controlled crossover study, 30
healthy volunteers consumed 30mg of hydroxytyrosol per day for a total of four weeks with two weeks washout between treatments. The hydroxytyrosol was supplemented either as HTEssence or as olive extract in comparison to placebo. olives and olive leaves and its extraction Results show a significant reduction of is complex and cost-intensive. With LDL cholesterol in the blood plasma by Wacker’s patented process, it is possible 9.4mg/dL (eight per cent) with HTEssence to synthesise a nature-identical substance (see Figure 1). High LDL levels are one main of much greater purity, free of unwanted factor for the occurrence of coronary heart byproducts, and with a defined amount diseases and arteriosclerosis. The NCEP of active ingredient. Available as an estimates that each one percent reduction odourless, water-soluble powder and in LDL cholesterol reduces the risk of liquid, the product is suitable for use in heart disease by one to two percent (see functional foods and dietary supplements, Figure 2). Accordingly, an LDL cholesterol such as tablets, capsules, energy bars and reduction of eight per cent may reduce the functional beverages. • risk for heart diseases by eight per cent or more. Wacker Chemie – www.wacker.com Due to its diverse modes of action, hydroxytyrosol is a popular ingredient in dietary Figure 2: High low density lipoprotein levels are a main factor for the occurrence of coronary heart diseases and atherosclerosis supplements. One drawback, until recently, was the way it was produced. In nature, hydroxytyrosol is found in
Figure 1: Results of a recent clinical human study show a significant reduction of LDL cholesterol with Wacker’s nature-identical hydroxytyrosol HTEssence in comparison to olive extract and placebo
Food Review | January 2018
I N D U S T RY U P DAT E
NUTRIPHARMASOLUTIONS January 2018 | Food Review
What are SA consumers’
Research conducted on behalf of leading global ingredients solutions provider Ingredion shows that consumers across EMEA want the food and drinks industry to focus on developing healthier, more nutritious food. Overall, 60 per cent of respondents believe this should be the industry’s top priority. Improving products’ nutritional content was found to be of importance, with 50 per cent of South Africans saying they would pay more for a similar but healthier product.
arried out among consumers across eight EMEA countries, including South Africa, Ingredion’s Food that Just Clicks Report* also shows that technology plays a significant role in how, when and where consumers access information on food and drink products. It discovered that 59 per cent of respondents use mobile technology to check the nutritional profile of food and drink products. When deciding whether to purchase a new food or drink brand, almost half (48 per cent) use technology to compare products before planning.
“The report indicates that consumers across EMEA are tech-savvy and are using devices, websites and apps to validate their buying decisions” Exploring consumer values, the research also examined potential areas of improvement for food and drink manufacturers. One area specifically noted by South African consumers was the demand for a reduction in undesirable ingredients in their products
Food Review | January 2018
Consumers want cleaner and healthier food
(60 per cent), namely sugar. Cutting down on packaging (37 per cent) and reducing processing (36 per cent) also ranked in their top three priorities. Additionally, new research indicates that transparency and accessibility to product content information is a high-priority for consumers. For food and beverage manufacturers, offering clear, accessible information on what their products contain could be the key to earning consumer trust in their brands while differentiating themselves from competition. The report indicates that consumers across EMEA are tech-savvy and are using devices, websites and apps to validate their buying decisions - whether at home, at work or on the spot in-store. With rapid advancements and uptake in mobile devices and technology, it’s likely
FAST FACTS THE FULL FOOD that Just Clicks report was launched at Food Ingredients Europe 2017. Find the full report at http://m.ingredion.com/ food_that_just_clicks to download a copy and to access further findings and analysis. Alternatively, visit emea.ingredion.com
that their use as a key information channel will only grow in the future. As the food and drink industry continues its clean label journey, enabling easy online access to product information, using simpler ingredients and prioritising health and sustainability will be key ways for food and beverage manufacturers to build trust in the years ahead. • *The research was carried out by MMR on behalf of Ingredion in September 2017. A total of 800 consumers, 100 from each of the following countries, took part in the survey - Germany, Iran, Kenya, Poland, Russia, South Africa, the United Arab Emirates and the United Kingdom.
Ingredion – emea.ingredion.com
The power of smart ingredients Food Ingredients Europe, held in November 2017 in Frankfurt, Germany, offered a perfect platform to introduce innovative smart ingredients to the global food and beverage industry. Of interest was the focus on new ingredients in infant nutrition.
new launches in the category grew by an average of 37 per cent a year from 2010 to 2016. ‘Numerous scientific studies have highlighted the positive contribution of whey ingredients during the early years of a child’s life. While whey protein is widely recognised for its rich content of essential amino acids, contributing to healthy growth, studies have also found that individual whey fractions offer specific health benefits. Our new concept harnesses these benefits to create complementary foods with added nutrition that help to smooth the way from exclusive breast-feeding or infant formula to the solid food eaten at the family meal.’
POSITIVES FOR INFANT BONE GROWTH
abies transition from a diet based exclusively on breast milk or infant formula to one that is based on solid foods. During this phase, they experience new tastes and textures, and the foundations are laid for a healthy diet and life-long wellbeing. Complementary food products can help to smooth the way during this critical time. Arla Foods Ingredients’ new Complementary Feeding range has harnessed the goodness of whey protein in a range of food product concepts that deliver benefits for gut health, allergy management, healthy growth and bone development. Product solutions in the new range include a smoothie, a yoghurt, a rusk and a porridge. They have been developed as templates that food and beverage companies can use to create finished products under their own brands, with minimum fuss. The solutions are formulated using specific whey protein fractions extracted from cows’ milk with targeted benefits: •L acprodan ALPHA-10 (smoothie, yoghurt, rusk, porridge) – Alpha lactalbumin supports healthy growth, healthy gut flora and reduces feeding-related gastrointestinal issues
•L acprodan DI-3071 (smoothie, porridge) – A partial whey protein hydrolysate to support comfort •P eptigen IF-3080 (smoothie, porridge) – An extensive whey protein hydrolysate for allergy management •L acprodan Whey Protein Concentrate (smoothie, yoghurt, porridge) – A whey protein concentrate to support healthy growth •C apolac (smoothie, yoghurt, porridge) – A milk mineral concentrate with calcium, phosphorus and magnesium for optimal calcium absorption and to support development of the teeth and bones. Anne Staudt Kvistgaard, senior manager science and sales development at Arla Foods Ingredients, remarks, ‘The market for complementary foods is buoyant. The Innova Database shows the number of
Infat Advanced Lipids’ SN-2 infant formula ingredient – may have the potential to support healthy bone growth. Palmitic acid is the most abundant saturated fatty acid in human milk, where it is primarily located in the SN-2 position. SN-2 palmitate is a well-established structured fat added to infant formulas. It is already known to offer a range of benefits for babies, including longer sleep duration and reduced crying. Researchers set out to explore the effect that SN-2 palmitate has on the length and quality of bones in a catch-up growth model. After restricting the diets of two groups of rats, one group was fed with a diet enriched with Infat– Advanced Lipids’ SN-2 palmitate ingredient – and the other with a standard diet. Weight gain was similar between the two groups and there were no adverse effects from either diet. However, rats in the Infat group scored higher on parameters such as humerus length. Values relating to bone quality also seemed higher in the Infat group, although the difference did not reach statistical significance. Researchers also analysed gene expression in the two groups and found that three genes in the liver showed an increase in the Infat group. They say these may be associated with growth and development in the epidermal growth plate. •
Arla Foods Ingredients – www.arlafoodsingredients.com Advanced Lipids – www.advancedlipids.com
January 2018 | Food Review
Break down that gluten
olerase G, a proline-specific endopeptidase or prolyloligopeptidase is the only dietary enzyme scientifically proven to help break down gluten in the stomach. It gives glutensensitive consumers following a gluten-free diet more freedom, as they no longer need to worry about accidentally consuming the residual gluten hidden in many foods. Found in wheat, barley and rye, gluten is a protein complex that is rich in an amino acid called proline. The human body cannot break down proline-rich proteins efficiently. This may be why up to 13 per cent of the world’s population is sensitive to dietary gluten.
Food Review | January 2018
One in four consumers try to avoid eating foods that contain gluten, this can be almost impossible when dining away from home. The ingredient specifically degrades the immunogenic parts within gluten proteins. Gluten-sensitive T-cells still react to gluten degraded by current commercial glutendigesting supplements, but not to gluten degraded with Tolerase G. The product has been deemed safe for use in the general population and tested in regulatory toxicity studies. Formulated by DSM, Tolerase G is supplied locally through Chempure. •
Chempure – www.chempure.co.za
IN SHORT… BACKED BY REGULATORY bodies in the US, EU, Canada, Australia and New Zealand, Tolerase G is an IP protected and very effective enzyme for gluten digestion in the stomach: • The only enzyme that is scientifically proven to digest proline-rich gluten epitopes in vitro, in a gastrointestinal model and in humans • Stable and active under low pH stomach conditions • Resistant to digestion by pepsin • Micro-granulated form with excellent flow ability and compressibility for use in capsules and tablets.
BeverageREVIEW SOUTH AFRICAN
January 2018 | Volume 8 | Number 01
Advanced technologies in juice processing
Kiss sugar goodbye New markets for particles, fibres and pulp
Maotai will soon be available in South Africa
Bye bye sugar THE NATIONAL COUNCIL of Provinces (NCOP) has passed the tax on sugary drinks, which is part of the Rates and Monetary Amounts and Revenue Law Amendment Bill. This marks the end of 18 months of negotiations on the tax that included four public hearings and a negotiation process in Nedlac. The tax, due to be implemented on 1 April 2018, will see the price of a can of Coca Cola increase by around 11 per cent. Initially Treasury proposed a tax of around 20 per cent on a can of Coca Cola. The current tax will levy 2.1 cents per gramme of sugar on all sweetened drinks, with the first four grammes of sugar per 100ml exempt as an incentive to encourage industry to reformulate its drinks to reduce their sugar content. South Africans are among the top 10 consumers of sugary drinks in the world. Research has shown that drinking just one sugary fizzy drink a day increases one’s chance of being overweight by 27 per cent for adults and 55 per cent for children. Diabetes alone claimed more than 25 000 lives in 2015, and public health facilities reported seeing 10 000 new diabetes cases every month last year. ‘While the tax is a victory for public health, it is around 11 per cent on a can and we would like it to be strengthened to 20 per cent to deter people,’ said Malawana. ‘We will also be monitoring how the proceeds of the tax are used to ensure that government uses the money for health promotion. ‘Over 30 countries worldwide are taxing sugary drinks, and South Africa joins Portugal, India, Saudi Arabia and Thailand who have passed similar taxes this year.’
Beverage Review | January 2018
China strengthens ties with local liquor industry SOUTH AFRICANS ARE big fans of Chinese food and could soon pair it with the Chinese national drink, Maotai. A delegation from China arrived in Cape Town late last year to investigate the trading environment in South Africa, find opportunities for cooperation and introduce South Africans to the Maotai brand. The delegation of sixty people participated in a wine country tour and met with potential Maotai distributors. ‘We are visiting South Africa to secure future business and seek collaboration opportunities with local companies. The fact that we brought such a large delegation indicates our level of purpose and intent to understand the local market and find companies to work with here,’ exclaims Bao Fang Li, general manager and director of Kweichow Moutai.
The demand for exotic fruit is increasing. The worldwide fruit purée concentrate market is valued at more than US$400m and is expected to grow to US$700m by 2026. By Maryke Foulds
imilar growth is expected in the exotic fruit purée concentrate market, predicted to reach US$274m by 2026. What is causing this increase and how can exotic fruit processors meet the demand without compromising quality? A global increase in baby food consumption is a significant factor. Growth in the fruit juice industry and an increasing demand for fruit smoothies and other products are contributing factors. Fruit juices tend to be made from juice concentrate, but manufacturers are starting to use purée concentrate instead. This shift provides consumers with a thicker, bettertasting, smoother drink. Exotic fruits include high quantities of fibrous material. This increases its consumer appeal from a health perspective. As better for you products become more popular, the demand for fruit purée concentrate will increase as will the varied ways it is processed. When it comes to juice processing, most fruits are crushed and juice is then extracted. As consumers look for better taste, a thicker consistency and keeping important nutrients intact, processors are responding by peeling the fruits and removing the skin, seed pockets and stones. This results in highquality concentrate and purée.
ADVANCED TECHNOLOGIES Fruit peeling is an important part of the juice and smoothie manufacturing process. Current methods involve certain fruits (peaches, apples and mangos) undergoing a lye peeling process. This sees produce pass through a boiling sodium hydroxide solution, which burns off the skin. The process uses large volumes of water and can lead to high levels of food waste, making it inherently inefficient. Technological advances in steam peeling have created significant advantages over lye peeling. These allow for reduction in water use, limits the amount of produce wasted and contributes towards a more sustainable process. Leading equipment manufacturers have developed innovations that can steam peel
and sort a range of fruits, including apples, TOP END MIXING mango, peaches, nectarines and papayas. Inoxpa CMC’s mixing unit is a skid These assist processors to overcome designed for fast dispersion of problems found in certain fruits, such hydrocolloid products such as as the removal of seed pockets carboxymethylcellulose (CMC), flours, in apples and pits in others. carbopol, pectin, guar or By helping in the removal xantham gum. These additives of these issues, processors are widely used in industry due can provide a higher quality, to their multiple properties as smoother drink. thickeners, jellifying agents, Using steam peeling to stabilisers and complexing remove skin to create a agents. Hydrocolloid compounds smooth consistent surface are usually available in dry around the outer surface and powder form, which must be inner core, means that diluted in water to obtain high fruit volumes can the desired colloidal be processed to a very solution. When these high quality with reduced powders meet water, waste. These high quality Mixing technology from Inoxpa lumps quickly form and peeled fruits form the basis it is difficult to obtain a of the concentrate and purées, used in homogenous mixture using a conventional many applications. agitator. To overcome this problem, the Tomra works closely with leading fruit mixing unit incorporates a roto-stator processing companies to evaluate steam mixer at the bottom of the tank that shears peeling processes for use in high volume the product, thereby increasing the waterfruit processing lines. The system enables additive contact area. A cowles-type agitator processors to peel quickly and efficiently, fitted in the tank allows the efficient so that the heat absorption of the fruit is circulation of the powder to the mixer lower significantly lower, in turn protecting it and head and helps improve the dispersion time. making for a superior product. When the process requires working with high
WHAT IMPACTS THE JUICE CATEGORY? The fuel price increase in the first quarter of 2017 and the subsequent rise in distribution costs An increase in sugar price, which affects certain fruit juices Packaging material costs are subject to currency fluctuations
Limited consumer disposal income
Scarcity of certain fruit in the market due to drought
January 2018 | Beverage Review
A DELICATE SCIENCE powder percentages, the use of hot water can be an important factor as this allows the viscosity to be significantly increased. For such cases, the available options include a heating jacket and the replacement of the cowles-type propeller with another suitable agitation element such as an anchor. The systems feature the following: •A IASI 316 stainless steel vertical body •V ertical agitator with cowles propeller •T ank bottom high-shear mixer •M aximum and minimum level monitoring probe • Tank-mounted sampling valve •P owder adding and inspection manhole •C lean-in-place (CIP) diffuser balls •M anual discharge butterfly valve •E lectrical control panel. •
Inoxpa – www.inoxpa.co.za JBT – www.jbt.co.za Tetra Pak – www.tetrapak.co.za
Juice processors are under pressure to deliver the beverage market with particles, fibres and pulp. This is challenging, as products are fragile and easily damaged during processing. CONSUMERS WANT NATURAL fruit fibres, which simulate the experience of drinking fruit in liquid form. Processing particles, fibres, and pulp is a delicate operation. It raises questions of how much damage is acceptable; where in the process damage is most likely to occur; variations i.e. ripeness or sugar content in raw material affecting the process and product, and how equipment exchangers can influence the final product. One of the best solutions is a dual aseptic line - one for each of the particle and liquid streams. Two streams are blended inline or in an aseptic tank before packs are filled. This process treats the particle and liquid streams optimally before joining them. A major benefit is that neither form is compromised since particles, fibres and pulp require longer heating time than liquid.
The challenge lies in delivering the right food safety processes. Processors must achieve the correct temperature at the centre of the product without overheating the liquid, which requires a lower temperature. A dual line is the best way to achieve this without compromising the liquid or solid phase. Other characteristics also influence design of the processing equipment. Heat exchanges for particles should have fewer tubes, sufficiently large for the particle size and with smooth inlets. It’s a delicate science. It is critical to have accurate heat transfer coefficients to calculate the correct sizes and also consider that particles increase mixing while in the tubes due to the turbulence they create. Getting that calculation right comes from deep practical knowledge and experience with the right organisational support to invest in the necessary innovation.
BLENDING AND MIXING SOLUTIONS CMC and Pectin in the Juice Industry
Beverage Review | January 2018
INOXPA SOUTH AFRICA
GAUTENG - SOUTH AFRICA Tel. +27 (0)11 794-5223 - email@example.com www.inoxpa.com
2018/01/16 10:42 AM
PackagingREVIEW SOUTH AFRICAN
January 2018 | Volume 43 | Number 1
s k n i y t i l s a t i h c g i Sptaeken to new he
Investments in growing aluminium sector proves fruitful
Eco-friendly dairy bottle wins two awards
Inks on the brink of growth
ITH ANOTHER YEAR ahead – I hope you had a relaxing break and are ready to take on 2018 in full force. Smithers Pira predicts that food-safe inks will grow at a fast rate in the coming years. This is attributed to pressures from brand owners whilst regulators see these inks adopted in larger amounts of food packaging. Increasing demands on packaging designs present new challenges to ink manufacturers. The intensity of competition in the inks and coatings market continues to proliferate as vendors invest in technological developments. This editon of PACKAGING REVIEW comprises a particular focus on the obligations of an ink provider, which you can read about on page 38. Inks that have been developed for use in flexographic printing are also featured on page 40. Enjoy the read!
Assistant Editor Aarifah.Nosarka@newmediapub.co.za
Christoph Riedlsperger and Len Engelbrecht
The deal’s officially sealed ALPLA’S TAKEOVER OF Boxmore Packaging, which was subject to legal and regulatory approval by the competition authorities, has been approved. The transaction, signed in July 2017, was approved without conditions. Alpla now holds 100 per cent of the issued share capital and has sole control of Boxmore Packaging. This acquisition is the largest for the Austrian manufacturer. The company owns 163 production plants in more than 43 countries. It will now have an additional nine plants in three countries and 1 000 more employees. The current Boxmore Packaging board and management team under the leadership of CEO, Len Engelbrecht will remain the same. Engelbrecht will take on the additional responsibility of integrating and managing the existing Alpla SA business. Alpla’s regional director for Africa, the Middle East and Turkey, Christoph Riedlsperger will oversee the combined business, which will fall under his divisional responsibilities. Riedlsperger says one of the critical deciding factors in this buyout was Boxmore Packaging’s well-established footprint in southern Africa and the Indian Ocean Islands. ‘We like how the company is managed and feel good chemistry with the management team,’ he concludes.
Air Products South Africa (Pty) Limited manufactures, supplies and distributes a diverse portfolio of atmospheric gases, specialty gases, performance materials, equipment and services to the Southern African region. Air Products touches the lives of consumers in positive ways every day, and serves customers across a wide range of industries from food and beverage, mining and petrochemicals, primary metal and steel manufacturers, chemical applications, welding and cutting applications to laboratory applications. Founded in 1969, Air Products South Africa has built a reputation for its innovative culture, operational excellence and commitment to safety, quality and the environment. In addition the company aims to continue its growth and market leadership position in the Southern African region.
Service that delivers the
Packaging Review | January 2018
Eco-friendlier dairy bottle bags two accolades DAIRYPACK, A DIVISION of Polyoak Packaging, won the gold medal in the sustainability category at the Gold Pack Awards, held last year on 22 November at the Inanda Club in Sandton. The company also bagged an international WorldStar Award 2018. These awards were for its green bottle that was developed in partnership with Woolworths. The HDPE bottle contains 30 per cent plant-based plastic derived from a renewable resource, Brazilian sugar cane. The green milk bottle has been described as a first for South Africa’s dairy industry. The project was made possible by the Brazil-based biopolymer producer, Braskem, through its innovations in polymer production. Following the same plastic production process, the plant-based polyethylene is chemically and structurally identical to conventional polyethylene. It provides the same quality and protection when used in food packaging. It can also be seamlessly mixed with a regular fossil-fuel alternative and is 100 per cent recyclable. ‘We are proud of what our partnership with Woolworths has achieved.
Incorporating bioplastics into our raw material feedstocks is one of many Polyoak initiatives that demonstrate our commitment to producer responsibility,’ says Hekkie van der Westhuizen, national executive at Dairypack. Last October, Polyoak Packaging joined the worldwide drive by plastics leaders to reduce the volume of plastic pellets ending up in the ocean. The company signed a pledge, as part of Plastics|SA’s Operation Clean Sweep, to prevent resin pellet, flake and powder loss finding its way to the sea. Jeremy Mackintosh, Polyoak’s group MD explains the importance of the public declaration. ‘Polyoak is proud to be one of the country’s biggest
Novus Holdings acquires ITB Manufacturing IN JUNE, THE Competition Commission South Africa approved the proposed merger between the two companies, which has now come into effect. Novus Holdings operates in the commercial print and manufacturing industries while ITB Manufacturing manufactures and supplies flexible plastic packaging solutions. The acquisition forms part of Novus Holdings’ business strategy to diversify into related and new markets to boost profitability and increase cash flow through sourcing new revenue streams for the group. ‘Acquiring ITB Manufacturing will allow Novus Holdings to access revenue streams outside of the print media sector, which to date has been the source of the majority of our income. This investment in the packaging industry further entrenches us in the broader industrial and manufacturing sectors and is complementary to our existing operations,’ says Keith Vroon, Novus Holdings Group CEO. The group, in conjunction with ITB Manufacturing plans to expand on the current ITB offering and gain organic growth in the flexible plastic packaging and wrap around label sectors. ‘We are delighted to join forces with the group of companies. We look forward to the opportunities of offering an expanded range of packaging solutions with an improved geographical footprint and an enhanced range of products and services from synergies with the technical and production capabilities of Novus Holdings,’ says Tim Stewart, MD of ITB Manufacturing. on ro Keith V
manufacturers of plastic packaging. Because we use large quantities of plastic pellets and flakes daily to produce items such as plastic bottles, closures and containers, it is important we adhere to strict environmental standards and take a leading role as a responsible producer. By signing the pledge, we want to highlight our commitment to making zero pellet loss a priority.’
Prioritise recycling THE LATEST PLASTICS recycling figures released by Plastics|SA reveal that South Africans are recycling more plastics than ever before. Anton Hanekom, executive director of Plastics|SA says the results of its annual survey into plastics recycling for the period ending December 2016 reveal there is a growing awareness of recycling and public pressure to recycle. This has resulted in more post consumer and post industrial plastics made available for reuse. ‘In 2016, 1.144 million tonnes of recyclable plastic entered the waste stream, of which 41.8 per cent was recycled in South Africa based on input tonnages. This is a year-on-year increase of 5.9 per cent,’ he explains. During this period, a growing number of organisations and consumer groups became actively involved in upstream collection efforts. This resulted in a positive impact on the number of plastics collected and recycled. Recycled tonnages have grown by 35 per cent since 2011. ‘The increase in recycling that was recorded was not as a result of increased plastic products that entered the market. In fact, 1.518 million tonnes of virgin polymer were converted into products in South Africa during this period – a mere 1.9 per cent increase compared to 2015,’ Hanekom adds. He says plastics manufacturing and recycling industries in South Africa and around the world have been taking strain over the past two years. ‘Toward the end of 2016, South Africa had 204 active recyclers, which mechanically reprocessed plastics materials such as plastic packaging. This provided formal, permanent employment to 6 140 staff and supported the informal employment of 51 500 waste pickers and collectors,’ he concludes. January 2018 | Packaging Review
I N D U S T RY TA L K
Global label production trends for 2018 Changing needs, greater acceptance of colour digital printing and demand for more personalised offerings continue to drive the global print label market. By Shawn Bezuidenhout
any product manufacturers are regularly frustrated by the label supply process that can manifest restrictive ordering volumes, inconsistent turnaround times, stocking implications and lack of flexible short run supply for those prototyping, special event or cobranding opportunities. Many producers are asking the questions: ‘Will producing short run labels in-house negatively affect my core business?’ and ‘Can an IT challenged owner easily adapt to take advantage of this new trend?’ The answers are simple. If you have the right partner, you can achieve exceptional results easily, adding maximum value to your brand and business.
There are so many technical choices that it can seem confusing if one doesn’t have a label producing and digital printing background. Specific industry demands like EU compliance, GHS and BS5609s need specific technologies. A reputable, experienced partner can help simplify the available options and their implementation. Of all the print label technologies, digital printing has witnessed the highest growth and this is expected to continue. This is likely to lead to new, but inexperienced South African equipment suppliers pushing technologies they may not completely understand themselves to try and capitalise on a booming market. We are already seeing traditional “photocopier sales type” entities entering this market damaging the reputation of digital and on-demand label solutions. This continued growth in digital label production is fuelled by global demands for increased customisation across a wide spectrum of industries and is not restricted to label production. Manufacturing businesses often don’t need the high quantities of a single label design required to make traditional flexo methods cost-effective for producers. Various reasons for this include that they simply don’t produce goods in such
Figure 1: Global printed label market by label type, 2009-19 ($ billion, constant 2013 prices and exchange rates; trillion A4 prints)
high volume quantities, label legislation changes on a regular basis in their industry, different retailers have different product labelling requirements, each item needs to be marked with unique information such as batch numbers or RFID, seasonal product labelling, clientele special demands or unique product differentiation etc. With the right digital label production system, short-run labels can be produced efficiently, cost-effectively and cut to any shape the client requires; and there is a vast array of media available from waterproof and chemical resistant options to metallic and transparent film options. Catering to the short-run labelling customer base is rapidly becoming an indispensable part of production and the traditional label production business. Many small and large manufacturers are opting to run their own digital label production facilities in-house, offering not only big cost savings but also control of production schedules, turnaround times and product flexibility. Digital print methods are growing rapidly and taking an increasing share. Labels can help secure and trace items throughout the supply chains, providing tamper evidence, and smart labels can chart the storage conditions of many items. South African businesses that have already embraced this in-house digital label production trend are showing clear signs of increased competitive advantage from a costing standpoint as well as flexibility of label design options and speed of execution. It is clear that these businesses are stretching ahead of the curve and will continue to exploit an advantage over competitors who can’t adapt to evolving market demands. Over the coming months we will provide more insight into the value behind incorporating in-house label production to your manufacturing business. We hope that by sharing information gained over more than 25 years’ digital experience, we will help you make the right decision for your situation. • (source: www.smitherspira.com)
SHAWN BEZUIDENHOUT is managing director of NSI 4 Africa Digital Labelling Technologies.
NSI 4 Africa Digital Labelling Technologies – www.nsi4africa.com
Packaging Review | January 2018
R I G I D PAC K AG I N G
Conversion opens A GROWTH PATH
Over the past four years, beverage giants have made huge investments to transform the steel industry into one that favours aluminium. PACKAGING REVIEW delves into the impact this has on the sector and country.
ince 2013, more than US$94 million aluminium cans, completing the transition (R1 258 billion) in capital investments from steel to aluminium cans in just a have been made by ABInbev, Cocafew years. Cola Southern Africa, Nampak Bevcan Prior to this, only two aluminium and Hulamin to convert the beverage can lines were running, but soon after, all industry from steel to aluminium. three lines were operational to meet the Not only did this step bring the region demand. The conversion of production in line with other major international lines allowed the company to produce markets such as the US, which eight can sizes at maximum changed to aluminium cans in speeds of up to 3 000 cans per the ’70s and ’80s, but it also minute, compared to 1 600 had a positive impact cans per minute on the on the industry’s old tinplate lines. recycling statistics. ‘The full scale plant is The industry body Recycling one beverage regarded as one of the can, saves the same representing the biggest aluminium can amount of energy needed interests of the local manufacturing facilities to burn a 100W bulb for metal packaging in the world,’ says Erik four hours. industry, Metpac-SA Smuts, Nampak’s group says the recycling rate executive for Bevcan. for used beverage cans in According to Smuts, the South Africa grew significantly environmental advantage of from only 18 per cent in 1993 to its the conversion is that up to present rate of around 72 per cent. 17 per cent less energy is used in the The organisation’s CEO, Delanie manufacturing process. This is because, Bezuidenhout believes South Africa’s amongst other savings, no external white conversion to aluminium played an coating is required. This has also reduced important role in increasing these the number of ovens needed. volumes. This is attributed to aluminium ‘A melting point of 660°C is required to cans’ infinite recyclability without loss of process and recycle aluminium compared strength or quality. to more than 1 300°C for steel. There ‘This makes aluminium recovery is also around a 60 per cent weight and recycling an economically viable reduction, which helps to minimise option for beverage can collectors in material and transportation costs. This the informal sector. Each year, millions results in a of rands flow into the scrap metals significantly and recycling industry, allowing an additional 2 000 to 3 000 people to earn a living or to supplement low incomes,’ Bezuidenhout explains. With a long tradition of continuous improvement and business excellence, Nampak Bevcan has become a preferred beverage can manufacturer in sub-Saharan Africa. The company has manufacturing plants located in Johannesburg, Pretoria, Cape Town, Angola and Nigeria. It also commissioned South Africa’s first aluminium beverage can production line at its Springs plant in Gauteng. By the end of 2014, all of its Gauteng can production lines were being converted to
DID YOU KNOW?
improved carbon footprint. Thanks to system advances, we’re also achieving notably enhanced print quality on aluminium cans at high speeds,’ he comments.
SITES ON HOME SOIL PROVE ADVANTAGEOUS Almost 95 per cent of Hulamin’s aluminium was previously provided in the form of virgin aluminium ingots. These were supplied by BHP Billiton’s Hillside smelter in Richards Bay, KwaZulu-Natal. As it takes about 20 times more energy to convert mined bauxite into aluminium than it does to re-melt a used beverage can, the company opted to invest in its own recycling operations to take advantage of the energy and production cost savings. Hulamin recently unveiled its R300 million state-of-the-art, scraprecycling facility designed to recycle used aluminium cans. The plant also extends its services to scrap storage, sorting, cleaning and melting – increasing the company’s onsite closed-loop recycling capabilities. As a result, Hulamin is almost reaching the target of sourcing 20 per cent of metal units from recycling. •
Metpac-SA – www.metpacsa.org.za The Nampak facility in Springs
“A melting point of 660°C is required to process and recycle aluminium compared to more than 1 300°C for steel”
January 2018 | Packaging Review
I N K S & C OAT I N G S
Keeping ink the right side of packaging Brand owners and consumers expect uncontaminated food and no adverse health effects from packaging materials. Ink providers are obligated to use appropriate materials when producing inks and follow good manufacturing practices to demonstrate compliance and minimise risk.
EXPOSURE ASSESSMENT FOR TOXIC HAZARDS WITHIN PRINTED PACKAGING applications, especially food packaging, exposure and migration factors are of key importance. The exposure assessment is a migration assessment that depends on several factors. These are the storage conditions of the packaging or the total amount of ink applied. The exposure highly depends on the consumer’s eating habits. The better the knowledge about consumed quantities and food types containing a specific migrant, the better the assessment.
database is accessible to all customers and can be downloaded,’ Johnstone adds. The company’s formulators address special customer requests, which are answered individually. ‘They also undertake communication with key accounts and brand owners globally.’
RAW MATERIAL INTRODUCTION PROCESS
uality, safety and compliance of packed material can only be guaranteed by implementing and adhering to strict rules along the packaging and processing chain. This is achieved by actively participating in legislative processes related to printing inks. These procedures are set out by organisations such as the Europen Printing Ink Association (EuPIA) and NAPIM, a trade association based in the US for the manufacturers of printing inks and supplier industries. Siegwerk addresses the need for safe inks used in packaging printing by identifying at the earliest possible stage how legislation will affect products. The company ensures compliance by applying the relevant legislation for printing inks. It also creates and provides legally required documents like the statements of ink composition. Jonathan Johnstone, MD of Siegwerk South Africa says the company abides by a number of guidelines to create added value for customers and brand owners while ensuring complete safety.
Packaging Review | January 2018
‘We perform risk assessments for intentionally added substances and nonintentionally added substances (NIAS) via the application of specific exposure limits or toxicological hazard assessments. These are conducted via a tiered exposure assessment, which includes migration modelling, a migration analysis amongst others,’ he explains.
THE ROLE OF FORMULATORS The company also provides guidance to its formulators on printing inks with optimised migration behaviours. There are lists available detailing which raw materials are suitable for various applications. ‘Formulators are responsible for customer requests related to packaging and product safety. They advise on product safety, regulatory compliance and enduser specifications. We have established a database on our HSE internet platform with documents covering all pertinent routine enquiries from our customers. This
The company has a stringent selection process for all raw materials used. ‘The strict criteria that governs this process also guarantees the safety of our products and employees. The raw material introduction process at Siegwerk is implemented worldwide and the approval of all these materials is provided through the Global HSE + Sustainability division,’ Johnstone explains. The raw material approval principles are: • compliance with an exclusion criteria (e.g. EuPIA on carcinogenics, mutagenics, reprotoxics and toxics) • compliance with stringent purity standards and a complete understanding of existing impurities in raw materials • evidence of the chemical registration of the components in each applicable region • full chemical composition for nutrition, pharma and hygiene (NPH) applications. Johnstone says these measures help to identify regulated materials in food contact, non-regulated but potentially migrating substances and NIAS. •
Siegwerk – www.siegwerk.com
Protecting food well with Siegwerk Printing inkS Siegwerk has developed special low-migration inks and varnishes for food packaging. Our printing inks for food packaging are largely based on renewable, vegetable resources. They are low in odor and free of mineral oils or genetically engineered organisms. They make an important
contribution to the production of sustainability-oriented packaging solutions. Siegwerk printing inks facilitate modern, light-weight packaging with intelligent functionality and optimized durability for food safety. “Save food” with efficient solutions from Siegwerk.
www.siegwerk.com Siegwerk Druckfarben AG & Co. KGaA Alfred-Keller-Str. 55 ∙ 53721 Siegburg ∙ Germany ∙ Phone: +49 (0) 2241 304-0 ∙ Fax: +49 (0) 2241 304-777 ∙ firstname.lastname@example.org
I N K S & C OAT I N G S
Ideas powered by chemistry
The role of inks and coatings in packaging can be crucial to the success or failure of printed products. Ongoing developments in the use of these speciality inks have opened up a new realm for packs to communicate and interact with consumers.
hromatic Technologies (CTI) is continuously innovating with inks and coatings. The company has taken traditional glow in the dark (GID) inks to the next level by developing them for use in flexographic printing. These inks, when exposed to light, are energised and radiates a glow effect. This lasts for about 15 minutes in the dark while a higher coat weight results in a stronger glow.
Packaging Review | January 2018
pack to sunlight. This interactive concept captured consumers’ attention and brought awareness to the promotion. The bags display a magnifying glass and a white circle until the pack is exposed to sunlight when Chester’s mischievous irreverent brand character appears from behind the magnifying glass. The company customdeveloped the orange and charcoal photochromic inks used on the packaging, which was qualified with the converter. Representatives from CTI then attended the production run to ensure complete satisfaction on The latest everyone’s part. Ink formulators require incorporation of According to in-depth knowledge of flexographic GID ink LaPierre, the the chemical and physical is a Doritos pack, interactivity of the properties of raw materials and how these affect or react launched in Mexico in package compels with one another and the 2017. The ink used on the customers to play with environment. Doritos packaging is a the packaging, rather solvent based ink. than treating it as a ‘The printers’ standard ‘product carrier’. printing process can be used Barry McCann, new launch to apply the GID ink. There is no leader for CTI says one of the challenges need for special technology to be utilised. of using smart technology is finding an By using high speed printing methods, these application that isn’t merely a ‘gimmick,’ but inks can be applied at a low incremental has a meaningful connection to the brand. cost. CTI’s flexo inks have also been used as ‘The ultimate goal is to lift product sales, a spot UV coating on the back side of offset but for lasting power, it has to speak to the presses where a spot UV curable coating can consumer in a way that reinforces the brand be applied. This is traditionally done with personality and promise.’ a raised plate, a chambered doctor blade CTI’s facility utilises a documented quality coater unit and a high cell volume anilox. It policy managed through an enterprise-wide gives a very strong glow,’ says Kevin LaPierre, quality management system. This ensures a senior account executive at CTI. products manufactured by the company He says the company’s speciality ink are of consistent high quality. The company products have also been used on Cheetos has achieved ISO 9001:2015 certification, and Frito Lays packs in North America. The registration number FM 655225. packaging converter of the Lays product won Each region has its own regulatory a Silver Achievement Award in 2016 from a requirements for using printing inks on US-based Flexible Packaging Association. food packaging for non-direct or non-food ‘This captured the attention of another contact applications. brand marketing team that wanted to do ‘This is why we have people dedicated something bigger and more interactive with to working with the brand or printer CTI’s photochromic, light-sensitive inks.’ to determine the suitability or use of CTI’s products as per these different EXPLORING NEW CHALLENGES requirements,’ LaPierre explains. The company recently expanded its Constantia Printing Inks, situated in photochromic ink capability throughout Edenvale, Gauteng is the local agent for CTI. • Mexico with the Cheetos-exclusive promotion, ‘Where is Chester’?. Constantia Printing Inks – The promotion involves Chester the www.constantia-inks.co.za cheetah being hidden on the packaging, CTI – www.ctiinks.com making him visible only when exposing the
DID YOU KNOW?
Official INX distributors for South Africa Constantia Printing Inks are proud agents for INX International, Salchi and CTI. INX Low Migration inks and coatings for non-food contact surfaces are created in a dedicated, state-of-the-art facility to meet stringent government regulations and compliance requirements. First impressions do make a difference, and one way for a brand to break through the clutter is with the use of special effects in the printing process. INX inks and coatings in this category include soft touch, pearlescent, raised glitter and spot gloss coatings; reticulation varnish; and fluorescent, foil stamp and metallic inks. With BiocopacPlus Salchi Metalcoat is developing the first bio-based varnishes for food packaging obtained from agro-industrial waste from the tomato industry. CTIâ€™s food safety technologies are on the cutting-edge of ensuring proper pasteurization, heat-sealing, and transportation. CTI provides technology that alerts consumers if a productâ€™s quality has been compromised in various stages within a supply chain. Options from CTI include; Thermochromics , Photochromics , Glow-in-the-dark , Reveal inks , Trigger inks,HPP indicators and Colour changing Plastic.
Tel: +27 011 524 0715 / 0716 Email: email@example.com Web: http://constantia-inks.co.za
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ADVERTISERS’ INDEX JANUARY 2018 AGT Foods..................................15....... www.agtfoods.com Air Products................................34....... www.airproducts.co.za Brewtech Engineering..............30....... www.brewtech.co.za Chempure....................................28....... www.chempure.co.za Constantia Printing Inks...........41....... www.constantia-inks.co.za Deltamune.....................................9....... www.deltamune.co.za Eptech..........................................42....... www.eptech.co.za Inoxpa SA....................................32....... www.inoxpa.com
Food Review | January 2018
KoelnMesse...................................8....... www.anugafoodtec.com Microsep..................................OBC....... www.microsep.co.za Nutri Pharma Solutions.............25....... www.nutripharmasolutions.com Rentokil Initial............................17....... www.rentokil.co.za Roff Industries............................19....... www.roff.co.za Savannah Fine Chemicals....OFC....... email@example.com Siegwerk......................................39....... www.siegwerk.com Spartan SME Finance............ IFC....... www.spartan.co.za
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Offering the following across all regions in SA: • Food Safety Implementation (BRC, FSSC 22000, GFSI, GLOBALG.A.P.) • Customised food safety training • Pre-certification audits • Coaching and mentoring of Food Safety Manager • Food Safety Systems Maintenance & Support • Tempo paperless FSMS software solutions firstname.lastname@example.org www.entecom.co.za
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within the food, beverage and health industries with innovative products, solutions and ideas. We are partnered with Firmenich and thus supply the world’s best flavours. Our state of the art facilities allow us to manufacture, blend and supply various, food colours, sweetener blends, juice compounds, cloudifiers, emulsions, health ingredients and Tea extracts. We also provide services in our powder and liquid facilities, offering our clients a unique and competitive edge.
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Food and beverage trends predicted for 2018 reveals a mixed bag of developments. Equipment and ingredients that assist with operational effi...
Published on Jan 23, 2018
Food and beverage trends predicted for 2018 reveals a mixed bag of developments. Equipment and ingredients that assist with operational effi...